Sustainable Wipes Products And Methods Of Forming Same

ABSTRACT

A wipes product includes a wipes container filled with at least one wipe substrate. The wipes container is formed at least partially from a first polymer and the first polymer is synthetic and at least partially derived from a renewable resource via a first intermediate monomeric compound. The wipes container includes a lid and a base such that at least one of the lid and the base comprises a bio-based content of about 10% to about 100% using ASTM D6866-10, method B. Methods of forming a wipes product are also provided.

FIELD OF THE INVENTION

The present disclosure generally relates to wipes products that dispensecleaning wipes and, more particularly, to a wipes product whichcomprises synthetic polymeric materials derived from renewableresources, where the materials have specific performance characteristicsmaking them particularly useful in the wipes product.

BACKGROUND OF THE INVENTION

Wipes products can include cleaning wipes generally sold in plastictubs, tubes or other containers, and a consumer typically extracts awipe for use by pulling the wipe through a hole or slot in thecontainer. In certain embodiments, the hole or slot is covered by a lid.Commonly, the plastic container or tub is sold pre-loaded with a supplyof wipes. Once a consumer depletes the original supply of wipes, theconsumer may discard the empty container and purchase a new pre-loadedcontainer or tub. Alternatively the consumer may refill the container ortub with a supply of fresh wipes and re-use the container or tub todispense the wipes.

Because of widely differing consumer tastes, manufacturers tend to makea wide variety of cleaning wipes. For example, some consumers desirescented wipes, while other consumers demand wipes that are free of alldyes, scents, or perfumes. Still other consumers desire wipes havinglotions such as aloe vera, lanolin, or other materials, often with orwithout the addition of alcohol. Still other consumers want flushablewipes, biodegradable wipes, gentle wipes, or wipes free of any lotion,alcohol, or other additives.

The development of wipes products is the subject of substantialcommercial interest. There is a great deal of art relating to the designof wipes products, the processes for manufacturing such wipes products,and the materials used in their construction. In particular, a greatdeal of effort has been spent in the development of materials exhibitingoptimal performance characteristics for use in wipes products.

Some of the materials used in current commercial wipes products,especially the container, are derived from non-renewable resources,especially petroleum. Typically, the components of the wipes product aremade from polyolefins such as polyethylene and polypropylene. Thesepolymers are derived from olefinic monomers such as ethylene andpropylene which are obtained directly from petroleum via cracking andrefining processes.

Thus, the price and availability of the petroleum feedstock ultimatelyhas a significant impact on the price of wipes products which utilizematerials derived from petroleum. As the worldwide price of petroleumescalates, so does the price of wipes products.

Furthermore, some consumers display an aversion to purchasing productsthat are derived from petrochemicals. In some instances, consumers arehesitant to purchase products made from limited non-renewable resourcessuch as petroleum and coal. Other consumers may have adverse perceptionsabout products derived from petrochemicals being “unnatural” or lessenvironmentally friendly.

Accordingly, it would be desirable to provide a wipes product whichcomprises a polymer at least partially derived from renewable resources,where the polymer has specific performance characteristics making thepolymer particularly useful in the wipes product.

SUMMARY OF THE INVENTION

In accordance with one embodiment, a wipes product comprises a containerand at least one wipe substrate. The container comprises a lid and abase. The base defines an interior space. The at least one wipesubstrate is at least partially disposed within the interior space. Thecontainer is formed at least partially from a first polymer, the firstpolymer is synthetic and is at least partially derived from a renewableresource via a first primary intermediate compound. The first primaryintermediate compound is monomeric. At least one of the lid and the basehas a bio-based content of about 10% to about 100% using ASTM D6866-10,method B.

In accordance with another embodiment, a container for a wipes productis formed at least partially from a first polymer. The first polymer issynthetic and at least partially derived from a renewable resource. Thecontainer comprises a base and a lid. The base defines an interiorspace. The interior space has a major opening. The base comprises abottom panel, a top ridge and at least one side panel. The lid comprisesa major portion and a minor portion. The minor portion is hingedlyconnected to the major portion. The major portion is configured to besecurable to the base to selectively facilitate closure of the majoropening. The major portion defines a minor opening. The minor openingcommunicates with the interior space. The minor portion is selectivelymoveable between a first position and second position. The minor portioncloses the minor opening when in the first position. The minor portionpermits access to the interior space through the minor opening when inthe second position. At least one of the base and the lid has abio-based content of about 10% to about 100% using ASTM D6866-10, methodB. At least one of the base and the lid has a density of from about 0.85g/cc to about 0.99 g/cc.

In accordance with yet another embodiment, the wipes product has a DropTest Failure Rate of zero when the wipes product is dropped 10 times orless. The wipes product comprises a container and at least one wipesubstrate. The container comprises a lid and a base. The base defines aninterior space. The at least one wipe substrate is at least partiallydisposed within the interior space. The container is formed at leastpartially from a first polymer, the first polymer is synthetic and is atleast partially derived from a renewable resource. At least one of thelid and the base exhibits a bio-based content of about 10% to about 100%using ASTM D6866-10, method B.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a wipes container having a lid with amajor portion and a minor portion;

FIG. 2 is a perspective view of the wipes container of FIG. 1 where theminor portion of the lid is in a open position exposing the orifice ofthe wipes container;

FIG. 3 is a perspective view of the wipes container of FIG. 1 where themajor portion and minor portion of the lid are in an open position;

FIG. 4 is a front view of the wipes container of FIG. 1, wherein thewipes container is closed and contains wipe substrates shown in dashedlines; and

FIG. 5 is a partially enlarged bottom view of an orifice illustrated inFIGS. 2-4.

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings. Some of the figures may have been simplified bythe omission of selected elements for the purpose of more clearlyshowing other elements. Such omissions of elements in some figures arenot necessarily indicative of the presence or absence of particularelements in any of the exemplary embodiments, except as may beexplicitly delineated in the corresponding written description. None ofthe drawings are necessarily to scale.

DETAILED DESCRIPTION OF THE INVENTION I. Definitions

As used herein, the following terms shall have the meaning specifiedthereafter:

“Bio-based content” refers to the amount of carbon from a renewableresource in a material as a percent of the mass of the total organiccarbon in the material, as determined by ASTM D6866-10, method B. Notethat any carbon from inorganic sources such as calcium carbonate is notincluded in determining the bio-based content of the material.

“Disposed” refers to an element being located in a particular place orposition.

“Film” refers to a sheet-like material wherein the length and width ofthe material far exceed the thickness of the material. Typically, filmsmay have a thickness of about 0.5 mm or less.

“Petrochemical” refers to an organic compound derived from petroleum,natural gas, or coal.

“Petroleum” refers to crude oil and its components of paraffinic,cycloparaffinic, and aromatic hydrocarbons. Crude oil may be obtainedfrom tar sands, bitumen fields, and oil shale.

“Renewable resource” refers to a natural resource that can bereplenished within a 100 year time frame. The resource may bereplenished naturally, or via agricultural techniques. Renewableresources include plants, animals, fish, bacteria, fungi, and forestryproducts. They may be naturally occurring, hybrids, or geneticallyengineered organisms. Natural resources such as crude oil, coal, andpeat which take longer than 100 years to form are not considered to berenewable resources.

“Agricultural product” refers to a renewable resource resulting from thecultivation of land (e.g. a crop) or the husbandry of animals (includingfish).

“Monomeric compound” refers to an intermediate compound that may bepolymerized to yield a polymer.

“Polymer” refers to a macromolecule comprising repeat units where themacromolecule has a molecular weight of at least 1000 Daltons. Thepolymer may be a homopolymer, copolymer, terpoymer etc. The polymer maybe produced via fee-radical, condensation, anionic, cationic,Ziegler-Natta, metallocene, or ring-opening mechanisms. The polymer maybe linear, branched and/or crosslinked.

“Synthetic polymer” refers to a polymer which is produced from at leastone monomer by a chemical process. A synthetic polymer is not produceddirectly by a living organism.

“Polyethylene” and “polypropylene” refer to polymers prepared fromethylene and propylene, respectively. The polymer may be a homopolymer,or may contain up to about 10 mol % of repeat units from a co-monomer.

“Communication” refers to a medium or means by which information,teachings, or messages are transmitted.

“Related environmental message” refers to a message that conveys thebenefits or advantages of the wipes product comprising a polymer derivedfrom a renewable resource. Such benefits include being moreenvironmentally friendly, having reduced petroleum dependence, beingderived from renewable resources, and the like.

“Wipe substrate” as used herein, refers to a cleaning article thatcomprises a substrate of one or more layers of nonwoven web.

The terms “nonwoven web” or “web” are used interchangeably herein, andrefer to a layer of individual fibers or threads that are interlaid, butnot in an identifiable manner as in a knitted or woven web. Nonwovenwebs may be made via processes known in the art, including but notlimited to: carding; airlaying; and wetlaying. Processes comprisingfilament spinning from resin and integrated webforming include, but arenot limited to: spunbonding; meltblowing; coforming; and formingspunbond-meltblown-spunbond composites. Fiber bonding processes of usemay include, but are not limited to: spunlacing (i.e.,hydroentanglement); cold calendering; hot calendering; air thru bonding;chemical bonding; needle punching; and combinations thereof.

II. Polymers Derived from Renewable Resources

A number of renewable resources contain polymers that are suitable foruse in a wipes product (i.e., the polymer is obtained from the renewableresource without intermediates). Suitable extraction and/or purificationsteps may be necessary, but no intermediate compound is required. Suchpolymers derived directly from renewable resources include cellulose(e.g. pulp fibers), starch, chitin, polypeptides, poly(lactic acid),polyhydroxyalkanoates, and the like. These polymers may be subsequentlychemically modified to improve end use characteristics (e.g., conversionof cellulose to yield carboxycellulose or conversion of chitin to yieldchitosan). However, in such cases, the resulting polymer is a structuralanalog of the starting polymer. Polymers derived directly from renewableresources (i.e., with no intermediate compounds) and their derivativesare known and these materials are not within the scope of the presentinvention, in that they are not considered to be at least partiallyderived from a renewable resource via an intermediate compound.

Synthetic polymers of the present disclosure can be derived from arenewable resource via an indirect route involving one or moreintermediate compounds. Suitable intermediate compounds derived fromrenewable resources include sugars. Suitable sugars includemonosaccharides, disaccharides, trisaccharides, and oligosaccharides.Sugars such as sucrose, glucose, fructose, maltose may be readilyproduced from renewable resources such as sugar cane and sugar beets.Sugars may also be derived (e.g., via enzymatic cleavage) from otheragricultural products such as starch or cellulose. For example, glucosemay be prepared on a commercial scale by enzymatic hydrolysis of cornstarch. While corn is a renewable resource in North America, othercommon agricultural crops may be used as the base starch for conversioninto glucose. Wheat, buckwheat, arracaha, potato, barley, kudzu,cassaya, sorghum, sweet potato, yam, arrowroot, sago, and other likestarchy fruit, seeds, or tubers are may also be used in the preparationof glucose.

Other suitable intermediate compounds derived from renewable resourcesinclude monofunctional alcohols such as methanol or ethanol andpolyfunctional alcohols such as glycerol. Ethanol may be derived frommany of the same renewable resources as glucose. For example, cornstarchmay be enzymatically hydrolyzed to yield glucose and/or other sugars.The resultant sugars can be converted into ethanol by fermentation. Aswith glucose production, corn is an ideal renewable resource in NorthAmerica; however, other crops may be substituted. Methanol may beproduced from fermentation of biomass. Glycerol is commonly derived viahydrolysis of triglycerides present in natural fats or oils, which maybe obtained from renewable resources such as animals or plants.

Other intermediate compounds derived from renewable resources includeorganic acids (e.g., citric acid, lactic acid, alginic acid, amino acidsetc.), aldehydes (e.g., acetaldehyde), and esters (e.g., cetylpalmitate, methyl stearate, methyl oleate, etc.).

Additional intermediate compounds such as methane and carbon monoxidemay also be derived from renewable resources by fermentation and/oroxidation processes.

Intermediate compounds derived from renewable resources may be convertedinto polymers (e.g., glycerol to polyglycerol) or they may be convertedinto other intermediate compounds in a reaction pathway which ultimatelyleads to a polymer useful in a wipes product. An intermediate compoundmay be capable of producing more than one secondary intermediatecompound. Similarly, a specific intermediate compound may be derivedfrom a number of different precursors, depending upon the reactionpathways utilized.

Particularly desirable intermediates include olefins. Olefins such asethylene and propylene may also be derived from renewable resources. Forexample, methanol derived from fermentation of biomass may be convertedto ethylene and or propylene, which are both suitable monomericcompounds, as described in U.S. Pat. Nos. 4,296,266 and 4,083,889.Ethanol derived from fermentation of a renewable resource may beconverted into the monomeric compound ethylene via dehydration asdescribed in U.S. Pat. No. 4,423,270. Similarly, propanol or isopropanolderived from a renewable resource can be dehydrated to yield themonomeric compound of propylene as exemplified in U.S. Pat. No.5,475,183. Propanol is a major constituent of fusel oil, a by-productformed from certain amino acids when potatoes or grains are fermented toproduce ethanol.

Charcoal derived from biomass can be used to create syngas (i.e., CO+H₂)from which hydrocarbons such as ethane and propane can be prepared(Fischer-Tropsch Process). Ethane and propane can be dehydrogenated toyield the monomeric compounds of ethylene and propylene.

Other sources of materials to form polymers derived from renewableresources include post-consumer recycled materials. Sources of syntheticpost-consumer recycled materials can include plastic bottles, e.g., sodabottles, plastic films, plastic packaging materials, plastic bags andother similar materials which contain synthetic materials which can berecovered.

III. Exemplary Synthetic Polymers

Olefins derived from renewable resources may be polymerized to yieldpolyolefins. Ethylene and propylene derived from renewable resources maybe polymerized under the appropriate conditions to prepare polyethyleneand/or polypropylene having desired characteristics for use in a wipesproduct. The polyethylene and/or polypropylene may be high density,medium density, low density, or linear-low density. Polyethylene and/orpolypropylene may be produced via free-radical polymerizationtechniques, or by using Ziegler-Natta catalysis or Metallocenecatalysts. Examples of such bio-sourced polypropylenes are described inU.S. Publication Nos. 2010/0069691, 2010/0069589, 2009/0326293, and2008/0312485; PCT Application Nos. WO2010063947 and WO2009098267. Otherolefins that can be derived from renewable resources include butadieneand isoprene. Examples of such olefins are described in U.S. PublicationNos. 2010/0216958 and 2010/0036173.

Such polyolefins being derived from renewable resources can also bereacted to form various copolymers, including for exampleimpact-modified copolymers or impact copolymers. In a particularembodiment, the impact-modified copolymer can include impact-modifiedpolypropylene (a copolymer of propylene and ethylene) andimpact-modified polypropylene (a blend of isotactic polypropylene andpolyisobutylene). Such copolymers and methods of forming same arecontemplated and described for example in U.S. Pat. Nos. 7,488,789;7,368,498; 7,259,211; 7,217,766; 7,109,269; 7,105,603; and 6,492,465.

In addition, the polyolefin derived from a renewable resource may beprocessed according to methods known in the art into a form suitable forthe end use of the polymer. The polyolefin may comprise mixtures orblends with other polymers such as polyolefins derived frompetrochemicals. Depending on the end use and form, the polyolefin maycomprise other compounds such as inorganic compounds, fillers, pigments,dyes, antioxidants, UV-stabilizers, binders, surfactants, wettingagents, and the like.

It should be recognized that any of the aforementioned syntheticpolymers (e.g., copolymers) may be formed by using a combination ofmonomers derived from renewable resources and monomers derived fromnon-renewable (e.g., petroleum) resources. For example, the copolymercan comprise propylene repeat units derived from a renewable resourceand isobutylene repeat units derived from a petroleum source.

Certain synthetic polymers described herein derived at least in partfrom a renewable resource exhibit desirable characteristics. In oneembodiment, these synthetic polymers can have a Melt Flow Index of about12 g/10 min to about 100 g/10 min; and in another embodiment thesynthetic polymers can have a Melt Flow Index of about 40 g/10 min toabout 60 g/10 min. The Melt Flow Index can be determined applying themethodology set forth in ASTM D1238-10.

In one embodiment the density of at least a portion of the container(e.g., lid and/or base) comprising these synthetic polymers can be fromabout 0.85 g/cc to about 0.99 g/cc; in a certain embodiment the densitycan be from about 0.89 g/cc to about 0.96 g/cc; and in a certainembodiment the density can be from about 0.92 g/cc to about 0.95 g/cc.It will be appreciated that these portions of the container comprisingthe synthetic polymers can include other components, such as fillers,pigments etc., which could cause the density to be greater or less thanthe ranges noted herein. The density of the containers comprising thesynthetic polymers can be determined applying the methodology set forthin ASTM D792-08. For example, a 20 mm×20 mm sample for densitydetermination is cut from a portion of the container using a suitablesharp blade. The density of the sample is determined according to ASTMD792-08 regardless of the thickness of the sample.

IV. Wipes Products Comprising the Synthetic Polymer Derived fromRenewable Resources

Selected embodiments are hereinafter described in detail in connectionwith the views and examples of FIGS. 1-5, wherein like numbers indicatethe same or corresponding elements throughout the views. FIGS. 1-4 showperspective views and a front view, respectively, of a wipes container10, for storing and dispensing wipe substrates 24 (as represented bydashed lines in FIG. 4). The wipes container 10 may include a base 11having a bottom panel 12, at least one side panel(s) 8 and a top ridge17. The at least one side panel(s) 8 can include a front panel 14, arear panel 16, a right panel 18 and a left panel 19. The base 11 canprovide a relatively stable means of support, for example, when thecontainer 10 is placed on a surface. In certain embodiments, the bottompanel 12 of the base 11 may be substantially flat and have a generallyrectangular shape. In certain embodiments, the base 11 may includefeatures such as commonly known feet or areas of increased friction. Itis to be appreciated, however, that the base 11, the front panel 14,rear panel 16, right panel 18 and left panel 19, or even the entirecontainer 10 may take any suitable shape desired or include any suitablefeature known in the art. Furthermore, it will be appreciated that thebase 11 can be formed as a unitary structure or comprise multiple piecesconstructed to cooperatively fit together to form the base. For example,in one embodiment, a bottom panel could be a separate piece thatattaches to a front panel, rear panel and side panels to form a base. Asmore clearly shown in FIG. 3, an interior space 22 may be defined by thebase 11 such that the interior space 22 can be above the bottom panel 12and between the front, rear, right and left panels 14, 16, 18 and 19.The interior space 22 may be configured to receive one or more wipesubstrates 24 as shown in FIG. 4, for example, in the form of a stack ofwipes or a roll of wipes. The interior space 22 may be sized as desired,for example, to store more than 10, 50, 100, 200, or even more than 500wipe substrates 24.

The container 10 may also include a lid 20 hingedly connected to therear panel 16. It will be appreciated that the lid 20 could also beconnected to the base 11 via other suitable means, including forexample, a free standing lid (not shown) which can attached to the topridge 17 of the base 11. As shown in FIGS. 1-4, the lid 20 may furtherinclude a major portion 26 and a minor portion 28 (which is more clearlyillustrated in FIGS. 1 and 2). When in the closed position the majorportion 26 of the lid 20 can be configured to be securable to the base11 by engaging the top ridge 17, as shown in FIGS. 1, 2 and 4. Thissecurable configuration facilitates opening and closing of a majoropening 30 thus restricting or permitting access to the interior space22 defined by the base 11. For example, the major portion 26 may berotated about hinge 27 until there is sufficient space for a consumer toplace a supply of wipe substrates 24 into the interior space 22 of thecontainer 10. The major portion 26 may then be returned to its initialposition so that the interior space 22 can be completely enclosed.

As shown in FIGS. 1 and 2, the minor portion 28 of the lid 20 can behingedly connected to the major portion 26 via a hinge 29. The majorportion 26 can define a minor opening 32 whereby the minor opening 32can communicate with the interior space 22 when the major portion 26 isin the closed position. The minor portion 28 can be configured toselectively move between a first position 33 and a second position 35 torestrict or permit access to the minor opening 32. While in the firstposition 33 (e.g., closed position), such as shown in FIG. 1, the minorportion 28 can restrict access to the minor opening 32. While in thesecond position 35 (e.g., opened position), such as illustrated in FIG.2, the minor portion 28 can permit access to the interior space 22. Asfurther illustrated in FIGS. 1, 2 and 4, the lid 20 can further includea locking mechanism (e.g., button 34) which can be associated with themajor portion 26 and configured to selectively maintain the minorportion 28 in the first position. The button 34 may be operativelyengaged with the minor portion 28 so that when a consumer properlymanipulates the button 34, the minor portion 28 of the lid 20 isrepositioned (e.g., opened) to expose the minor opening 32 and anorifice 36 (the orifice 36 may be configured as described in more detailhereinbelow). For example, the button 34 may retract and/or reposition alocking arm (not shown) that resists the force of a lifting mechanismsuch as a spring (not shown) or the like. In this example, once thelocking arm is properly repositioned, the spring may then applysufficient force to at least partially open the minor portion 28 of thelid 20. It is to be understood that the actuating means is not limitedto a button, but may include any actuating means for opening the lid ofa wipes container known in the art.

In an embodiment the container herein comprises a lid and a base and isformed at least partially from a first polymer, the first polymer issynthetic and is at least partially derived from a renewable resourcevia a first primary intermediate compound, the first primaryintermediate compound being monomeric, and at least one of the lid andthe base comprises a bio-based content of about 10% to about 100% usingASTM D6866-10, method B. Thus the container can be formed in whole or inpart by one or more synthetic polymers described herein which arederived from a renewable resource. For example, the base of the wipescontainer can be formed from a synthetic polymer derived from arenewable resource, but the lid of the container can be formed from asynthetic polymer derived from a petroleum source. It is contemplatedthat the wipes container can comprise a first synthetic polymer which isderived from a renewable resource such that anywhere from about 10% toabout 100% of the container is formed from the first synthetic polymer.

As noted herein, the lid 20 of the container 10 may include an orifice36 for accessing wipes 32 stored inside the container 10. For example,the orifice 36 may be configured such that a consumer is able to extracta wipe substrate 24 stored in the container 10 through the orifice 36.While the orifice 36 is shown in FIGS. 2-4 as being disposed on themajor portion 26 of the lid 20, it is to be understood that the orifice36 may be disposed on any suitable panel 14, 16, 18 and/or 19 asdesired. As further illustrated in FIGS. 2-5, the orifice 36 can includea sheet 38 and a continuous slit 40. The sheet 38 can have a top surface39 and bottom surface 42. The continuous slit 40 can extend across thetop surface 39 and the bottom surface 42 of the sheet 38. The continuousslit 40 can be sized to allow for a wipe substrate 24 to pass from theinterior space 22 of the base 11 to a location outside of the container10 as it is pulled and extracted by a consumer. It will be appreciatedthat the continuous slit 40 can have a variety of differentconfigurations, for example, a continuous slit can form a straight path(as shown in the embodiment of FIG. 5), a curved path, or any othersuitable configuration to assist in controlling the removal of wipesubstrates from the interior space 22 of the container 10. It will beappreciated that an orifice may take any suitable shape desired orinclude any suitable feature known in the art.

The orifice may be made from a relatively rigid material such asthermoplastic materials including polypropylene (PP), polyethylene (PE),polystyrene, polyethyleneterephthalate (PET), polypropylene/polyethyleneco-polymers, and combinations thereof. A relatively rigid orifice madefrom a thermoplastic material will typically have a thickness of about 1mm or from about 0.4 mm to about 2 mm. However, it is to be understoodthat any thickness of orifice may be suitable for use herein, asdesired. The orifice may be made from a relatively flexible materialsuch as a thermoplastic material such as films and/or laminate filmsmade from polypropylene, polyethylene, polystyrene,polyethyleneterephthalate, polyvinylchloride, oriented polypropylene,and combinations thereof. A relatively flexible orifice made from athermoplastic material will typically have a thickness of about 70 μm ormicrons, or from about 20 to about 400 μm or microns. The relativelyflexible orifice material may also be an elastomeric material such as athermoplastic elastomer such as styrenic block copolymer elastomers suchas styrene-butadiene-styrene elastomers,styrene-ethylene-propylene-styrene elastomers, styrene-isoprene-styreneelastomers, thermoplastic polyurethanes, plasticized PVC, andcombinations thereof. In certain embodiments, a relatively flexibleorifice made from a thermoplastic elastomer may have a thickness of fromabout 10 μm to about 3 mm. The relatively rigid orifices may result inincreased dispensing forces compared to relatively flexible material atleast in part due to the relative differences in flexibility in the twomaterials. The present orifices may include the characteristics asdescribed in the following patent and patent publications: U.S. Pat.Nos. 6,766,919; 6,592,004; 6,523,690; U.S. Publication No. 2008/0135572,the entire disclosures of which are hereby incorporated by referenceherein.

As shown in FIG. 4, the container 10 can be loaded with at least onewipe substrate 24, thereby forming a wipes product 9. The wipesubstrates 24 of the present disclosure may include one or more layersof nonwoven web. The wipe substrates 24 may also include one or morelayers of other material, as desired. The wipe substrates may have abasis weight of from about 30 to about 120 grams per square meter (gsm);from about 40 to about 70 gsm; or from about 50 to about 60 gsm. Thenonwoven suitable for use herein may be made by any means commonly knownin the art, such as, for example spunbonding and meltblowning. Thepresent wipe substrates can be formed from materials and by methodsdescribed in the following patent, patent applications and patentpublications: U.S. Pat. No. 4,100,324; U.S. Publication Nos.2005/0214335 and 2003/0104747; WO 2002/053365 and WO 2002/053003, theentire disclosures of which are hereby incorporated by reference herein.

Likewise, the nonwovens suitable for use herein may be consolidatedusing any means commonly known in the art, such as, for examplehydroentanglement, thermal calender bonding, through air thermalbonding, chemical bonding, needlepunching, and the like. The wipesubstrates can be formed by a process known as hydroentanglement. Asused herein, the term “hydroentanglement” generally means a process ofmaking a nonwoven through the treatment of a starting substrate. Thetreatment typically comprises the steps of supporting a layer of loosefibrous material on an apertured member, and subjecting the layer towater pressures that are sufficient to cause the individual fibers tomechanically entangle with other fibers and possibly other web layers ofa substrate. The apertured member can be made from any suitable surfaceincluding, but not limited to: a woven screen, a perforated metal plate,and the like. In certain embodiments, the method of making a nonwovenweb may include the steps of carding followed by hydroentanglement. Thepresent wipe substrates can be formed via hydroentanglement and othermethods described in the following patent publications U.S. PublicationNos. 2008/0135572 and 2005/0125877; and WO 2010/125545, the entiredisclosures of which are hereby incorporated by reference herein.

The wipe substrates can be formed from any of the synthetic polymers,individually or in combination, as described herein. The wipe substratescan be formed from the same or different synthetic polymers from whichthe wipes container is formed.

Nonwoven webs and fibrous layers used herein may be made from fiberschosen to provide desired end properties in the wipe substrateincluding, but not limited to: softness, thickness, and strength.Examples of suitable fibers include thermoplastic fibers,non-thermoplastic fibers and mixtures thereof. The fibers andcombinations of fibers may additionally comprise a certain percentage ofeach layer of the laminates as: multi-component, or conjugate fibers,such as bicomponent fibers; biconstituent fibers; non-round fibers; andcombinations thereof.

Wipe substrates according the present disclosure may have a plurality offirst and second regions that provide a sensation of texture to aconsumer. The texture may cause a consumer to perceive the wipesubstrates as having the thickness and feel typically associated withcloth, even when the wipes are pre-moistened. The texture may alsoprovide the wipes with good cleaning and liquid retentioncharacteristics.

The present wipe substrates and/or nonwoven layers from which they canbe made may be imparted with texture via methods described in thefollowing patent applications and publications: U.S. Pat. Nos.5,143,679; 5,518,801; 5,650,214; 5,691,035; 5,914,084; 6,114,263;6,129,801; 6,383,431; 5,628,097; 5,658,639; and 5,916,661; WOPublication Nos.: 2003/0028165A1; WO 2004/059061; WO 2004/058117; and WO2004/058118; U.S. Publication Nos.: 2008/0135572; 2005/0125877;2004/0131820A1; 2004/0265534A1; WO 2004/058117A1 (U.S. patentapplication Ser. No. 10/737,306); and WO 2006/009997A2 (U.S. patentapplication Ser. No. 11/155,805).

Various types of disposable wipe substrates are available. Such wipesubstrates can include dry products or saturated or pre-moistenedproducts. Saturated or pre-moistened products are used in a variety ofdifferent wiping and polishing applications. Pre-moistened wipesubstrates may be treated with an antibacterial agent and packaged assanitary wipes products.

The wipe substrates disclosed herein may include one or more personalcare composition that are commonly known to be included in wipesubstrates and/or suitable for cleaning the body of a child. Nonlimitingexamples of such personal care compositions may be found in U.S.Publication Nos. 2005/0125877; 2005/0008680; 2005/0008681; and2006/0058210. Any portion of a wipe substrates may be coated with alotion as is known in the art. Examples of suitable lotions includethose described in U.S. Pat. Nos. 5,607,760; 5,609,587; 5,635,191; and5,643,588.

The wipe substrates disclosed herein may include one or more hardsurface cleaning composition that are commonly known to be included inwipe substrates and suitable for cleaning various hard surfaces.Nonlimiting examples of such hard surface cleaning compositions may befound in U.S. Publication No. 2009/0124525.

The wipes container and/or the wipe substrates can be partially or fullycovered with an overwrap package. The overwrap package may comprise avariety of materials including, but not limited to, thermoplastic films,nonwovens, wovens, foils, fabrics, papers, cardboard, elastics, cords,straps, and combinations thereof. Other suitable package structures andoverwraps are described in U.S. Pat. Nos. 4,846,587; 4,934,535;4,966,286; 5,036,978; 5,050,742; and 5,054,619. In certain embodiments,the overwrap package comprises a synthetic polymer (e.g., a polyolefin)derived form a renewable resource such that it is formed at leastpartially from a fourth polymer, the fourth polymer is synthetic and isat least partially derived from a fourth renewable resource via a fourthprimary intermediate compound, the fourth primary intermediate compoundis monomeric, the overwrap package comprises a bio-based content ofabout 10% to about 100% using ASTM D6866-10, method B. Moreover, theoverwrap package may be in the form of a film. Such overwrap package canbe formed from any of the synthetic polymers, individually or incombination, as described herein.

The overwrap package is not limited in size; however, in certainembodiments, the size of the overwrap package should be no greater thanis required to contain the wipe substrates and/or container.

The container, wipe substrates, and/or overwrap package can be formedfrom the same or different synthetic polymers, as disclosed herein, thatare at least partially derived from a renewable resource via anintermediate compound, wherein the intermediate compound is monomeric.

V. Communicating a Related Environmental Message a Consumer

The present invention may further comprise a related environmentalmessage or may further comprise a step of communicating a relatedenvironmental message to a consumer. The related environmental messagemay convey the benefits or advantages of the wipes product comprising apolymer derived from a renewable resource. The related environmentalmessage may identify the wipes product as: being environmentallyfriendly or Earth friendly; having reduced petroleum (or oil) dependenceor content; having reduced foreign petroleum (or oil) dependence orcontent; having reduced petrochemicals or having components that arepetrochemical free; and/or being made from renewable resources or havingcomponents made from renewable resources. This communication is ofimportance to consumers that may have an aversion to petrochemical use(e.g., consumers concerned about depletion of natural resources orconsumers who find petrochemical based products unnatural or lessenvironmentally friendly) and to consumers that are environmentallyconscious.

The communication may be effected in a variety of communication forms.Suitable communication forms include a package label with an indicia,store displays, posters, billboard, computer programs, brochures,package literature, shelf information, videos, advertisements, internetweb sites, pictograms, iconography, or any other suitable form ofcommunication. The information could be available at stores, ontelevision, in a computer-accessible form, in advertisements, or anyother appropriate venue. Ideally, multiple communication forms may beemployed to disseminate the related environmental message.

The communication may be written, spoken, or delivered by way of one ormore pictures, graphics, or icons. For example, a television or internetbased-advertisement may have narration, a voice-over, or other audibleconveyance of the related environmental message. Likewise, the relatedenvironmental message may be conveyed in a written form using any of thesuitable communication forms listed above. In certain embodiments, itmay be desirable to quantify the reduction of petrochemical usage of thepresent wipes product compared to wipes products that are presentlycommercially available.

The related environmental message may also include a message ofpetrochemical equivalence. Some renewable, naturally occurring, ornon-petroleum derived polymers are known. However, these polymers oftenlack the performance characteristics that consumers have come to expectwhen used in wipes products. Therefore, a message of petroleumequivalence may be necessary to educate consumers that the polymersderived from renewable resources, as described herein, exhibitequivalent or better performance characteristics as compared topetroleum derived polymers. A suitable petrochemical equivalence messagecan include comparison to a wipes product that does not have a polymerderived from a renewable resource as described herein. For example, asuitable combined message may be, “Wipes Product Brand A with anenvironmentally friendly material is just as effective as Wipes ProductBrand B.” This message conveys both the related environmental messageand the message of petrochemical equivalence.

VI. Method of Making a Wipes Product Having a Polymer Derived from aRenewable Resource

The present disclosure further relates to a method for making a wipesproduct comprising a synthetic polymer derived from a renewableresource. The method comprises the steps of providing a renewableresource; deriving an intermediate monomer from the renewable resource;polymerizing the intermediate monomer to form a synthetic polymer andincorporating the synthetic polymer into a wipes product. The presentdisclosure further relates to providing one or more of the wipesproducts to a consumer and communicating reduced petrochemical usage tothe consumer. The synthetic polymer derived from renewable resources mayundergo additional process steps prior to incorporation into the wipesproduct.

In accordance with another embodiment, a method for making a wipesproduct comprises the steps of providing a first renewable resource,deriving a first intermediate monomeric compound from the firstrenewable resource, polymerizing the first intermediate monomericcompound to form a first polymer that is synthetic, and incorporatingthe first polymer into a wipes product. The wipes product comprises acontainer and at least one wipe substrate. The container comprises a lidand a base. The base defines an interior space. The at least one wipesubstrate is at least partially disposed within the interior space. Atleast one of the lid and the base exhibits a bio-based content fromabout 10% to about 100% using ASTM D6866-10, method B.

VII. Validation of Polymers Derived from Renewable Resources

A suitable validation technique is through ¹⁴C analysis. A small amountof the carbon dioxide in the atmosphere is radioactive. This ¹⁴C carbondioxide is created when nitrogen is struck by an ultra-violet lightproduced neutron, causing the nitrogen to lose a proton and form carbonof molecular weight 14 which is immediately oxidized to carbon dioxide.This radioactive isotope represents a small but measurable fraction ofatmospheric carbon. Atmospheric carbon dioxide is cycled by green plantsto make organic molecules during photosynthesis. The cycle is completedwhen the green plants or other forms of life metabolize the organicmolecules, thereby producing carbon dioxide which is released back tothe atmosphere. Virtually all forms of life on Earth depend on thisgreen plant production of organic molecules to grow and reproduce.Therefore, the ¹⁴C that exists in the atmosphere becomes part of alllife forms, and their biological products. In contrast, fossil fuelbased carbon does not have the signature radiocarbon ratio ofatmospheric carbon dioxide.

Assessment of the renewably based carbon in a material can be performedthrough standard test methods. Using radiocarbon and isotope ratio massspectrometry analysis, the bio-based content of materials can bedetermined. ASTM International, formally known as the American Societyfor Testing and Materials, has established a standard method forassessing the bio-based content of materials. The ASTM method isdesignated ASTM D6866-10.

The application of ASTM D6866-10 to derive a “bio-based content” isbuilt on the same concepts as radiocarbon dating, but without use of theage equations. The analysis is performed by deriving a ratio of theamount of organic radiocarbon (¹⁴C) in an unknown sample to that of amodern reference standard. The ratio is reported as a percentage withthe units “pMC” (percent modern carbon).

The modern reference standard used in radiocarbon dating is a NIST(National Institute of Standards and Technology) standard with a knownradiocarbon content equivalent approximately to the year AD 1950. AD1950 was chosen since it represented a time prior to thermo-nuclearweapons testing which introduced large amounts of excess radiocarboninto the atmosphere with each explosion (termed “bomb carbon”). The AD1950 reference represents 100 pMC.

“Bomb carbon” in the atmosphere reached almost twice normal levels in1963 at the peak of testing and prior to the treaty halting the testing.Its distribution within the atmosphere has been approximated since itsappearance, showing values that are greater than 100 pMC for plants andanimals living since AD 1950. It's gradually decreased over time withtoday's value being near 107.5 pMC. This means that a fresh biomassmaterial such as corn could give a radiocarbon signature near 107.5 pMC.

Combining fossil carbon with present day carbon into a material willresult in a dilution of the present day pMC content. By presuming 107.5pMC represents present day biomass materials and 0 pMC representspetroleum derivatives, the measured pMC value for that material willreflect the proportions of the two component types. A material derived100% from present day soybeans would give a radiocarbon signature near107.5 pMC. If that material was diluted with 50% petroleum derivatives,for example, it would give a radiocarbon signature near 54 pMC (assumingthe petroleum derivatives have the same percentage of carbon as thesoybeans).

A biomass content result is derived by assigning 100% equal to 107.5 pMCand 0% equal to 0 pMC. In this regard, a sample measuring 99 pMC willgive an equivalent bio-based content value of 92%.

Assessment of the materials described herein is done in accordance withASTM D6866. The mean values quoted in this report encompasses anabsolute range of 6% (plus and minus 3% on either side of the bio-basedcontent value) to account for variations in end-component radiocarbonsignatures. It is presumed that all materials are present day or fossilin origin and that the desired result is the amount of biobasedcomponent “present” in the material, not the amount of biobased material“used” in the manufacturing process.

In one embodiment, the wipes product can include a wipes container suchthat at least one of the lid and the base exhibits a bio-based contentvalue from about 10% to about 100% using ASTM D6866-10, method B. Inanother embodiment, a wipes product can include a wipes container suchthat at least one of the lid and the base exhibits a bio-based contentvalue from about 25% to about 100% using ASTM D6866-10, method B. In yetanother embodiment, a wipes product can include a wipes container suchthat at least one of the lid and the base exhibits a bio-based contentvalue from about 50% to about 100% using ASTM D6866-10, method B. It isfurther contemplated that the wipes substrates and the overwrap packagediscussed herein can also have bio-based content values similar to thoseof the wipes container.

In order to apply the methodology of ASTM D6866-10 to determine thebio-based content of any of the components (e.g. container, wipesubstrates, overwrap) of the wipes product, a representative sample ofthe component must be obtained for testing. In one embodiment, theentire component can be ground into particulates less than about 20 meshusing known grinding methods (e.g., Wiley® mill), and a representativesample of suitable mass taken from the randomly mixed particles.

VIII. Test Methods

Prior to testing, any outer film wrap or cardboard sleeve is removedfrom the outside of the wipes product. All samples are conditioned at73°±3 F.° (23°±2C.°) and a relative humidity of 20-70 percent for aperiod of at least 4 hours prior to testing. Testing is begun withinfive minutes after the wipes product has been removed from thepreconditioning atmosphere.

A. Torque Test

The Torque Test measures the torque in inch-pound needed to remove thebutton 34 from the wipes container. It is an indicator of the forcerequired if a child attempts to remove the button from the wipescontainer. If the button 34 does not have a free edge opposite of itshinge, the Torque Test Failure Rate is recorded as zero. The measurementis made using a torque gauge, such as a Chatillon DFS-R Series torquegauge (Largo, Fla.) or equivalent having a load cell capable of 50in-lbs at an accuracy of ±0.2 in-lb fitted with a screw clamp used togrip the button 34. The clamp gripping surfaces are 0.5 in. long by 0.25in. wide. The clamp shall be capable of holding the button 34 firmly andtransmitting a torsion force.

For testing, the minor portion 28 of the lid 20 is removed from theproduct. The container 10 and lid 20 are held in a stationary vice toimmobilize the container and lid during testing, such that the unhingedside of the button 34 is directed upward. The button is secured betweenthe faces of the clamp midway between the hinged edge and the distaledge applying sufficient force that the button will not slip as torsionforce is applied. Torque is then applied to the button 34 at a rate of0.6 to 0.8 inch/sec. in a clockwise direction to a maximum of 10.1in-lbs or until a failure or release of the button has occurred. ATorque Test Failure Rate is considered zero if no part of the button 34separates from the wipes product. If failure or release of the buttondoes occur, record the torsion force to ±0.1 in-lbs.

B. Tension Test

The Tension Test measures the force needed to remove the button 34 fromthe wipes container. It is an indicator of the force required if a childattempts to remove the button from the wipes container.

If the button 34 does not have a free edge opposite of its hinge, theTension Test Failure Rate is recorded as zero. The measurement is madeusing a force gauge, such as a Chatillon DFE-50 Force Gauge, (Largo,Fla.) or equivalent having a load cell capable of 50 in-lbs at anaccuracy of ±0.2 in-lb fitted with a screw clamp used to grip the button34. The clamp gripping surfaces are 0.5 in. long by 0.25 in. wide. Theclamp shall be capable of holding the button 34 firmly and transmittinga tension force.

For testing, the minor portion 28 of the lid 20 is removed from theproduct. The container 10 and lid 20 are held in a stationary vice toimmobilize the container and lid during testing, such that the unhingedside of the button 34 is directed upward. The button is secured betweenthe faces of the clamp midway between the hinged edge and the distaledge applying sufficient force that the button will not slip as torsionforce is applied. The button is then rotated 90 degrees such that it isdirected perpendicular to the plane of the lid of the product. Force isthen applied to the button 34 at a rate of 0.6 to 0.8 inch/sec.perpendicular to the plane of the lid to a maximum of 9.0 in-lbs oruntil a failure or release of the button has occurred. A Tensile TestFailure Rate is considered zero if no part of the button 34 separatesfrom the wipes product. If failure or release of the button does occur,record the peak force to ±0.1 in-lbs.

C. Drop Test

The Drop Test measures the failure of the wipes product if dropped on astandard surface. It is an indicator of the failure rate if a childdrops the wipes product. Each wipes product is tested whole with thewipes inside the container. The impact surface consist of a ⅛-inch(0.3-centimeter) nominal thickness of type IV vinyl-composition tile,composition 1-asbestos free, as specified by paragraphs 1.2 and 3.1.4 ofInterim Amendment-1(YD), dated Nov. 14, 1979, to the FederalSpecification entitled Tile, Floor: Asphalt, Rubber, Vinyl,Vinyl-Asbestos, SS-T-312B, dated Oct. 10, 1974. The test surface restsupon at least a 2.5-inch (6.4-centimeter) thickness of concrete. Theimpact area shall be at least 3 square feet (0.3 square meter).

The wipes product is dropped from a random orientation from a height of4.5 feet±0.5 inch (1.37 meters) onto the impact surface. After eachdrop, the wipes product is allowed to come to rest and examined andevaluated before continuing. The same wipes product is dropped ten timesor until any portion of the wipes product breaks loose. If upon impact,the minor portion 28 or the lid 20 pops open, close before the nextdrop. A Drop Test Failure Rate is considered zero if no part of thewipes product breaks loose within 10 drops. If any portion or fragmentof the wipes product breaks loose, record the number of drops at whichthe failure occurs.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this document conflicts with any meaning or definition of thesame term in a document incorporated by reference, the meaning ordefinition assigned to that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for making a wipes product comprising asynthetic polymer derived from a renewable resource comprising the stepsof: a) providing a first renewable resource; b) deriving a first primaryintermediate compound that is monomeric from the first renewableresource and polymerizing the first primary intermediate compound toform a synthetic polymer that is a first polymer; c) incorporating thefirst polymer into a wipes product container comprising: i. a lid and abase, wherein the base defines an interior space; d) providing at leastone of the lid and the base with a bio-based content of about 10% toabout 100% measured by ASTM D6866-10, method B.
 2. The method of claim1, wherein the wipes product further comprises at least one wipesubstrate at least partially disposed within the interior space.
 3. Themethod of claim 1, wherein the wipes product has a Drop Test FailureRate of zero when the wipes product is dropped 10 times or less.
 4. Themethod of claim 1, wherein at least one of the lid and the basecomprises a density of about 0.85 g/cc to about 0.99 g/cc.
 5. The methodof claim 4, wherein at least one of the lid and base comprises a densityof about 0.89 g/cc to about 0.96 g/cc.
 6. The method of claim 1, whereinthe first polymer has a Melt Flow Index of about 12 g/10 min to about100 g/10 min.
 7. The method of claim 6, wherein the first polymer has aMelt Flow Index of about 40 g/10 min to about 60 g/10 min.
 8. The methodof claim 1, wherein at least one of the lid and the base comprises abio-based content of about 25% to about 100% measured by ASTM D6866-10,method B.
 9. The method of claim 8, wherein at least one of the lid andthe base comprises a bio-based content of about 50% to about 100%measured by ASTM D6866-10, method B.
 10. The method of claim 1, whereinthe first polymer is a copolymer comprising monomers selected from thegroup consisting of propylene, ethylene, butadiene and combinationsthereof.
 11. The method of claim 1, further comprising the steps of:deriving a first secondary intermediate compound that is monomeric fromthe first renewable resource prior to forming the first primaryintermediate compound.
 12. The method of claim 11, wherein the firstsecondary intermediate compound is selected from the group consisting oforganic acids, sugars, monofunctional alcohols, polyfunctional alcohols,organic aldehydes, organic esters, and combinations thereof.
 13. Themethod of claim 1, wherein the first polymer is a polyolefin selectedfrom the group consisting of polypropylene, polyethylene, andcombinations thereof.
 14. The method of claim 1, further comprising thesteps of: providing a second renewable resource; deriving a secondprimary intermediate compound that is monomeric from the secondrenewable resource and polymerizing the second primary intermediatecompound to form a synthetic polymer that is a second polymer; andincorporating the first polymer and the second polymer into thecontainer.
 15. The method of claim 2, further comprising the steps of:providing a third renewable resource; deriving a third primaryintermediate compound that is monomeric from the third renewableresource and polymerizing the third primary intermediate compound toform a synthetic polymer that is a third polymer; incorporating thethird polymer into the wipe substrate comprising a bio-based content ofabout 10% to about 100% measured by ASTM D6866-10, method B.
 16. Themethod of claim 15, wherein the first polymer and the third polymer aredifferent.
 17. The method of claim 2, wherein the wipe substratecomprises a personal care composition.
 18. The method of claim 2,wherein the wipe substrate comprises a hard surface cleaningcomposition.
 19. The method of claim 2, further comprising the steps ofhydroentangling the wipes substrate.
 20. The method of claim 2, whereinthe wipes product further comprises an overwrap package.
 21. The methodof claim 20, wherein the overwrap package at least partially covers atleast one of the container and the wipe substrate.
 22. The method ofclaim 20, further comprising the steps of: providing a fourth renewableresource; deriving a fourth primary intermediate compound that ismonomeric from the fourth renewable resource and polymerizing the fourthprimary intermediate compound to form a synthetic polymer that is afourth polymer; incorporating the fourth polymer into the overwrappackage comprising a bio-based content of about 10% to about 100%measured by ASTM D6866-10, method B, wherein the overwrap package is afilm.
 23. The method of claim 1, further comprising a label, wherein thelabel provides an indicia to communicate an environmental message to aconsumer.